Pad formation method, assembly and pad produced thereby

ABSTRACT

A foam cushion pad formation assembly that includes a conveyance assembly having at least one moving conveyor component presenting a pad shape formation surface, which surface is convoluted and arranged to shape sealed enclosures of a pad chain received by the conveyance assembly. A separation device is provided to separate shaped pads of the pad chain received by said conveyor device. The shaped pads include convoluted surface that are formed by way of gripping projection and recesses combinations in the moving conveyor component. Embodiments include sensing for non separated pads from a downstream end of the bag chain, pad chain separation enhancement devices, and various control system including the requirement of confirmation of separation before feeding a new pad enclosure as in one containing liquid polyurethane precursor chemicals. An embodiment includes a pad chain path disruption sensor and a form feed control which implements the formation of pad enclosures free of filler material in a bridging region between the outlet end of the enclosure formation means and the conveyance assembly.

This application claims the benefit of U.S. Provisional Application No.61/136,005 filed on Aug. 5, 2008.

CROSS REFERENCE TO RELATED APPLICATIONS

As an example of a conventional method for manufacturing a flat,rectangular foam cushion or pad, the process starts when foam filledbags are produced such as in a conventional Foam-in-bag (FIB) system. Anexample of a conventional FIB system is found in U.S. Pat. No. 7,331,542to IntelliPack, Inc. of Tulsa Okla. USA, and which patent isincorporated herein by reference.

BACKGROUND DISCUSSION

A conventional method for manufacturing a flat, rectangular foam cushionor pad further includes a flat cushion making module which isconventionally comprised of two linear conveyors, each with a flat belt,mounted so that their belts are opposed and substantially parallel toeach other.

Known in the art is a process of making flat, rectangular, foam cushions(sometimes referred to as “pads”), as in the formation of pads in thefoam packaging industry. Current techniques and methods used by existingpad molders are described as follows: Contemporary Methods forManufacturing Flat, Rectangular, Foam Cushions

-   -   a. The opposing conveyor belts are spaced apart to the desired        thickness of the ultimate flat foam cushion—usually between one        to two inches of thickness.    -   b. Each conveyor belt moves at substantially the same speed,        with one conveyor rotating in a clockwise direction and the        other rotating in a counterclockwise direction so that the pads        are pulled into the gap by the conveyors relative motions. The        conveyors start and stop simultaneously so that they move as a        synchronized pair to prevent shearing of the flat foam cushions        as they move.    -   c. The conveyors conventionally are set up in either a vertical        or horizontal orientation.

The foam filled bags exit the FIB bagger which is positioned so that thedescending bags will be dispensed in the general direction of the gapbetween the belts of the moving conveyors. In reality, current flatcushion molding systems require an operator to feed the bags (that comedown or out from the FIB system) into the gap between the conveyors.Otherwise, the not yet cured bags have a tendency to fold over orotherwise miss-feed into the conveyors causing the foam bags to burstwithin the machine. This is commonly known as a “foam-up”.

Thus, in such a conventional feed operation;

-   -   a. Both belts advance as the bag exits the FIB machine to        essentially pull or drag the foam filled bag into the gap        between the conveyor belts as the bag exits from the output        portion of the FIB system.    -   b. For satisfactory operation, it is conventional in the        industry that a human operator assists in getting the bags to        feed properly into the conveyor gap.    -   c. The foam filled bag must be pulled into and fully constrained        by the opposing conveyor belts early in the foam expansion cycle        so that the rising foam inside the bag forms itself to the gap        (sized to the desired cushion thickness) between the opposing        belt surfaces.    -   d. If the foam expands excessively prior to the bag getting        pulled into the gap between the conveyors, the conveyors may not        be able to pull the forming bag in, and it will jam up the entry        zone essentially stopping the process until the jam is cleared.    -   e. In conventional systems the process timing is mainly        determined through testing and experimentation. The timing of        the process is generally based on the type of foam being used,        the speed of the conveyors, and other factors.

The foam rises and solidifies while contained between the conveyorbelts.

-   -   a. The foam expansion in the bag is restricted and controlled by        the distance of separation between the belts. For example, if        the belts are spaced one inch (2.54 cm) apart the final flat        cushion will be one inch (2.54 cm) thick.    -   b. Typical flat cushion thicknesses range between V2 inch        (1.26 cm) to 3 inches (6.62 cm).    -   c. Typical flat foam cushion molding systems have built-in means        of adjusting the spacing between the conveyors while maintaining        them in a parallel orientation. This is usually done with a        manually driven crank and chain arrangement.    -   d. This allows the flat cushion user to adjust cushion thickness        to suit the application.

The expanding foam will generate a pressure in the range of 3 pounds persquare inch so the support structures of the forming conveyors must berobust enough to handle these loads without undue deflection.

-   -   a. To maintain flatness each belt in conventional systems        features a stationary, rigid, and flat backer plate mounted        directly behind the belt.    -   b. The belts slide over the backer plates so the plates require        a low coefficient of friction to minimize drag.    -   c. The backer plates and their support structures must be rigid        and strong so as to remain essentially flat under the loads        generated by the pressure of the rising foam.    -   d. The rigid backer plates insure that the finished foam        cushions will be basically flat.    -   e. Also, the drive motors on each belt must be strong enough to        move the belts with high friction loads generated by the        expansion of the foam pushing the belt into its backer plate.        These loads can be in the hundreds of pounds and the required        motors may be larger than what would typically be associated        with the size of conveyor involved.

The flat foam cushions move, as they cure and harden, contained betweenthe belts along their axis of motion.

-   -   a. The curing flat cushions are confined within the gap between        the conveyor belts until the foam is sufficiently cured to        retain its intended shape as flat and rectangular when removed        from between the conveyors.    -   b. If the flat foam cushions are taken out from between the pair        of conveyors too soon the foam will not be sufficiently cured,        and the foam cushions will not hold their desired flat shape.

Flat cushion width is primarily determined by the width of the film usedto form the flat cushion. Typical widths range from 12 to 30 inches.

After the foam in the cushion has cured sufficiently so as to retain itsflat shape, the conveyors will move it along until it drops out at theend of its travel.

-   -   a. As they fall out of the conveyor output, the flat foam        cushions can be collected in storage or accumulator bins—they        can be used by a packer—or they can fall onto another conveyor        to take them away for use or storage at a remote location.

The flat foam cushion production rate can be increased by lengtheningthe conveyors.

-   -   a. It generally takes at least 20 seconds for a typical        illustrative cushion to cure to a point that it can be removed        from the constraining conveyor belts. For some of the denser        foam formulations this minimum time can be much longer than the        aforementioned 20 seconds as in one minute.    -   b. Longer belts allow for more curing time per cushion and        faster production rates.

Longer belted systems will have a greater flat cushion per minute outputup to the limitations of the bag making module.

-   -   c. It is believed that there exists in illustrative conventional        systems flat foam cushion molders capable of running at up to 26        cushions per minute but in reality running at the limiting        factor of the output rate of the bag making module is typically        the norm.

The conventional systems generally suffer from the drawback of not beingsufficiently generally fully automated in the formation of flat foamcushions or well suited for running without a human operator.

-   -   a. That is, it is considered by Applicants that suitable flat        foam cushion production systems in the industry and using        current technology are of a nature that requires monitoring and        assistance from an operator to prevent foam ups.    -   b. The most common problem occurs when a corner or an edge of a        bag catches and gets folded over as it enters the gap between        the molding conveyors.    -   c. When the film is folded, the effective bag volume is        restricted and has a lesser capacity with which to contain the        expanding foam which has already been dispensed in the quantity        required for the anticipated bag volume.    -   d. When this happens, a bag rupture and a possible explosion of        foam can occur if the available bag volume cannot hold the        amount of foam dispensed into the bag.    -   e. These ruptures and/or explosions, often called foam-ups, can        be especially messy and difficult and time consuming to clean.    -   f. Another problem is that the flat cushions, if not properly        oriented, will jam inside the conveyor. These jams can also        cause a foam-up as succeeding bags continue to enter the        conveyor system and an operator is not available to shut the        system down in a timely manner.

Problems such as those described above are common in the foam cushionpackaging industry such as in the production of cured polyurethane flatpanel packaging cushion inserts.

Problems such as those described above for the foam cushion packagingindustry can also be experienced in the production of other “pad”components (e.g., enclosures (typically flexible) that enclose materialwhich is placed in the enclosure (which material is typically flexibleat the outset and forms as to be less flexible such as in a curing orsolidifying during cooling down or setting, etc.)). Examples of otherpackaging industries that can experience problems such as thosedescribed above include, for example, the food industry, the chemicalindustry (e.g., plastics) and construction powdered mixes, etc.,although expanding types of materials are the more problematic.

SUMMARY OF THE INVENTION Operation Description for Embodiments of thePresent Invention

In a first embodiment of the present invention, the operation of a padformation system is described as follows. The process starts with bagsbeing manufactured by using an enclosure formation device as in aFoam-in-bag (FIB) system such as that described in U.S. Pat. No.7,331,542 to IntelliPack Inc., but with a setting that is different thanthe preferred setting described in U.S. Pat. No. 7,331,542. That is,there is provided an enclosure formation device in the form of a bagformation means with a bag making module as a component of the padformation system of the present invention. This enclosure or “bag”formation means can take on a wide variety of forms other than thatdescribed in U.S. Pat. No. 7,331,542 inclusive of other materialcontaining enclosures for which pad formation is beneficial.

That is, in an embodiment, as in one using plastic film based bags,unlike the standard mode of processing in the above noted FIB method,the bags are preferably not cut and separated from the web by a cut wiremounted onto the heated jaw at the exit of the bagger or with onedirectly associated with the FIB bagger (e.g., a cutter supported on acommon support platform). Instead of the standard mode of cutting andseparating bags as they exit the bagger module in the above noted U.S.'542 FIB system, the present invention does not implement a cutting atthis point (as by not powering up a resistance cut wire or by way ofremoving the cut wire associated with the bag module cutter with heatedjaw featured in the '542 patent).

As described below, the bags are still sealed; preferably, however, withseparate top and bottom seals as by the sealing technique carried out inthe FIB system of U.S. '542 FIB system (e.g., a wire at a temperaturesuitable for forming a seal bond but not a separation cut).

In an preferred embodiment of the present invention, with the cut wirenot powered up or removed from the heated combination cutting/sealingjaw of the FIB bagger, the bags exiting the FIB bagger remain attachedvia the seal webbing region as they exit from the output of the bagmaking module and enter the below described pad formation assembly orpad formation means. An additional, alternate embodiment includesretaining a chain series of bags with a partial interconnection betweenrespective bags as in a perforated cut line or a ribbon or tabattachment either by the inclusion of additionally applied material(e.g., one or more series of interconnecting ribbons) and/or baginterconnection tabs formed by a less than continuous or full lengthcutting (e.g., a cut line that is centered but not of full lengthrelative to the width/length of bag being cut). As seen from thediscussion below the maintenance of bag interconnection has advantagesrelative to the below described pad formation assembly operation, and acomplete or non-interrupted web is preferred in some setting as bettersuited for the pull of a bag chain through a pad formation assembly.Alternate, less preferred embodiments include, for example, sealing andcutting with the bag formation means (e.g., a single seal-cut line orcombination seal and complete cut lines) and running individual bagsthrough the below described pad formation assembly of the presentinvention instead of a bag chain. Mode toggle means is also featuredunder an embodiment of the present invention wherein logic control andoperator menu or a control panel allows the operator to toggle betweendifferent techniques (e.g., interconnected (full and/or partialinterconnection) bag run though the pad formation means ornon-interconnected, individual bag run through mode) either through thepad formation assembly or upon a removal of the pad formation assembly—which allows an operator to use the bagger in alternate modes dependingupon the operator's present needs.

A second component of the pad formation system of the present invention(which second component itself is representation of an invention in andof itself) includes a pad formation assembly or pad formation means thatis preferably positioned directly downstream relative to the bag outputlocation of the bag formation means as to avoid having to rely on anoperator to feed manually the formed bags to the pad formation assembly.Alternate (less preferred) embodiments of the present invention include,however, embodiments wherein an operator feeds bags to the pad formationassembly (e.g., based on an operator at least partially manuallypositioning bags such as one within arms length of the output of the bagformation means and the input of the pad formation assembly or based onan operator being remote from the bag formation means when inputtingbags into the pad formation assembly as in a quick transfer to arelative closely positioned pad formation assembly with the distancedepending in many embodiments on the cure period for the material (e.g.,a longer curing time in the foam can provide for more time before thebag expands to a level that makes it difficult to feed into the padformation systems input). Because of the characteristics of the foam infoam pads (e.g., urethane foam), as in those utilized in pads forpackaging or insulation, the pad formation embodiments described hereinare particularly well suited for handling such situations. For example,urethane foam (and like reactionary products) has the properties orrising slowly with minimized reactionary force, of highly moldable priorto setup and cure. These properties of foam pads render the disclosedembodiments described herein well suited for such applications.

In one embodiment, the bags are not cut from the web, and the entire web(e.g., the formed bag chain web) is pulled into the pad forming gapbetween the below described conveyor components. For example, the bagchain web is pulled into a gap formed between a belt and a fixed inposition platen (or some alternate conveyance assembly combination ofconveyor components as in one with a second conveyor belt or somealternate moving conveyance means as in a moving platen, etc.). Apreferred embodiment of the pad formation assembly comprises a drivenconveyor belt and a non-moving platen. The number of bags in the web canbe continuously run without any predetermined breaks in the chain orthere can be a predetermined number of bags per desired bag chain weblength depending on, for example, a continuous run setting or apredetermined bag chain web bag count (e.g., variable by menu setting)or less preferably there is utilized a single independent bag feedoperation (e.g., a one bag setting in the above-described potential bagchain setting count which is a standard “FIB” system setting describedabove and is thus a less desired setting when a present pad formationassembly is being utilized with the FIB system, but can be madeavailable nonetheless).

In an embodiment a continuous setting (e.g., a full roll of supply filmconverted into a continuous bag chain of the same representative length)or a relatively high number bag chain count (e.g., greater than five (5)bags in chain) is implemented. This allows the web of bags to travelthrough the pad formation assembly, which in a preferred embodiment is acushion forming system, as a single entity (e.g., an interconnectedchain of bags with end-to-end seal webbing linkage).

The feeding of a single entity web of bags under embodiments of theinvention helps in avoiding the main causes of bag explosions and/or bagjams that afflict earlier conveyor based pad molding systems asdescribed above. However, as described below, there is a requirement foradded complexity in providing a downstream cutting mechanism away fromthe convenient seal wire location of the FIB system jaws which isconsidered to be a reason why the conventional systems cut at the bagmaking module output in conventional systems.

The feeding of a single entity, continuous web of bags under embodimentsof the invention is one factor, when utilized, that allows for fullautomation, free of operator intervention, unlike existing conveyorbased pad molding systems (e.g., those that cut individual bags with astandard bagger and then attempt to feed those not yet cured, cut bagsinto an adjacent conveyor based pad molding system). As seen below,however, with some embodiments described herein this involves theinclusion of additional equipment and method steps for a preferredhandling of a bag chain web, as in the addition of means for a propershut down sequence which places one or more non-filled bags outward ofthe bag making module to avoid trying to feed in expanded bags during arestart, as well as means for avoiding the potential for furthercomplicating a jam up situation upon the attempt to feed in additionalbags into the pad formation assembly when a jam up occurs downstream. Asexplained below, however, embodiments include features that enableoperation of a bag chain web system despite the above noted obstaclesthat led away from conventional systems implementing the same.

For example, in one embodiment of the pad formation assembly there isfurther featured a draw-in monitoring sensor device (e.g., a sag ordroop sensor or bag chain web draw in confirmation sensor device) whichprovides a means to detect if the web is not being properly drawn intothe conveyor system. The draw-in monitoring sensor device preferablycomprises means for confirming proper web bag travel and means for anautomated shutdown of the pad formation operation (e.g., via a shutdownof the bagger operation and downstream pad formation assembly) if thereis sensed a potential problem in web bag travel as when a droop (as inmore than a typical droop used in a normal bag chain feed to ahorizontal conveyor) in the bag chain web is detected. In an embodiment,the draw-in monitoring sensor device includes the use of a photoeyeworking as a sensor in the sensor device.

In an embodiment of the pad formation assembly, there is furtherfeatured a conveyor that comprises a projection-recess series as in a“corrugated” or sinusoidal profile conveyor belt or other conveyancemechanism that imparts a convoluted surface in the pads formed.

Unlike conventional conveyor based, flat cushion molding systems, anembodiment of the invention produces a foam cushion that issubstantially different in that there is produced, for example, a padthat has one corrugated surface and only one flat surface (e.g., oneside having a convoluted or corrugated surface with the opposite sidehaving a smooth or less convoluted surface).

An embodiment also preferably makes use of only a single moving conveyorcomponent unlike the standard conveyor based, flat cushion moldingsystems which require two juxtaposed and moving conveyor componentsrunning in the formation of flat cushions in their flat cushion moldingsystem. Further that one non-moving conveyor component can be a smoothplaten from one end to the other without any interruptions or cavities.Further, in an embodiment each pad produced from the received bag chainhas a multi-projection convoluted surface as in one with repeating andcontinuous projection and recess combination across a full major exposedsurface of the pad.

Also, under an embodiment, the bags are preferably not separated fromthe bag chain web until the output end region of the conveyor system,and then there is preferably provided separation means comprising anautomated cut position sensing system for use with a bag chain webcutting mechanism to achieve cut implementation in the bag chain webwith the separated bag being separated from the upstream remaining bagchain web at the output end region of the conveyor.

For example, in one embodiment there is provided a cut position sensingsystem that comprises a sensor switch mechanism as in a microswitch or aplurality of the same, preferably mounted above and/or below the movingweb and also preferably near the output end of the conveyor (e.g., oneor two microswitches positioned above the moving web and positioned at alocation that is suited for establishing a cut region within a foot ofthe output end of the conveyor). The sensing system provides means forsensing a cut zone as in sensing a seal webbing portion of the bag chainweb that is not filled with foam as in the web region film formedbetween the two seals such as the non-foam filled end-to-end sealwebbing areas formed by the above-described sealing mechanism (e.g.,spaced apart non-cutting, but plastic film bonding seal wires of theheated jaw in the FIB system described above). While more cumbersome inmost environments, an embodiment can also feature alternate sensingmeans and/or trigger timing implementation means (e.g., one or moresensors sensing a sloped side end(s) of a conveyed bag by contact oroptical photosensing or the like or initiation upon detection of aninitial full height level detection location for a conveyed bag andcarrying out a suitable timing to trigger cutting in a suitable area asin the noted no-foam region between pads, and/or using optical markingsor alternate cutting location triggering means to set in place, forexample, a coordinated timing sequence with an activated cuttermechanism). Thus, a variety of triggering means methods can be reliedupon in the separation means for separation device or that function todetermine a present location of the bag chain web relative to the cuttermechanism, to determine the relative timing needed between bag chain webmovement and cutter mechanism operation, and to achieve bag separationfrom the bag chain web at the desired point and location in time.

In one embodiment the sensor system features a single microswitchassembly that is preferably mounted less than 6 inches (e.g., 2 or 3inches) upstream of the cutting location as in the location where aheated cutting wire of one or more cutting jaws contacts the webmaterial.

Also, in an embodiment of the pad formation assembly, the cut zone isabout ¾ inches wide, and thus the separation means with cut sensingsystem and cutting mechanics are designed to be sufficiently accurate asto implement a suitable cut within that relatively limited lengthrelative to either a stationary pad pair or, alternatively, a cuttermechanism that moves or is arranged so as to allow for a moving bagseries at the time of cut implementation (e.g., a cam operated cuttersystem, as in one or more cutters supported on a cutter support conveyortrack which can be independent or integrated with a bag movingconveyor).

In one embodiment, the cutting mechanism or cutter means comprises apair of cutting jaws with one or both being adjustable as in each beingpneumatically driven toward the other such as with air cylinders builtinto a linear thruster mechanism with dual guide shafts, and with thecutting mechanism preferably being associated (e.g., supported) by thepad formation assembly and not the bag formation means.

Relative to an embodiment of the cutting device or means for cutting,one linear thruster is mounted below the web and one mounted above.Also, relative to this arrangement in the cutting device, when thecutting device is actuated both jaws preferably move simultaneously sothat they meet near the plane of web motion.

As a cutting mechanism of the cutting device there is preferablyprovided a heated wire (e.g., Nichrome wire of about 0.015″ in diameter)that is mounted to the lower jaw with the upper jaw providing a suitablecompression contact anvil surface or vice versa or with both beingprovided with cutting elements as in a double contact heat resistancewire or component arrangement.

A cutting means embodiment features an arrangement that provides for thehot wire severing the bag from the web when the jaws come together,although other arrangements are also featured as in perforations thatare separated there or further downstream by, for example, roller feedspeed up relative to the web travel speed inclusive of an outfeedconveyor having corresponding projection recess gripping profiles as tocatch the corrugated surface of a pad leaving the pad conveyanceassembly. Alternatively, a perforated bag chain web can be produced foruse at a later time and/or location by having the operator or additionalremote equipment separate individual bags from the bag perforated bagchain web. Preferably additionally featured is a no-cut and cut switchmode control that is also preferably provided together with a controlsystem associated with the pad formation assembly that enables anoperator to choose (or toggle between) which mode is desired.

In a preferred embodiment the cutting means operates such that the bagsare cut by the hot wire (or other cut device or means such as a laser(or an alternate focused heat applicator), mechanical device (as in asharp edged blade) or fluid based cutting (as in a high pressure jet offluid, etc.) a few inches downstream from the microswitch or alternatesensor for triggering the cutting means.

Also, the cutting mechanism of an embodiment of the present inventionpreferably features a cut wire that is powered by a constant voltagedriver so that the cutting wire stays at a relatively constanttemperature (as compared for example to a less preferred impulse basedsystem, which impulse based cutting wire systems are used inconventional FIB systems and which impulse based system do not feature arelatively constant temperature in the wire or resistance element).

An embodiment of the pad formation assembly also features an outfeeddevice as in an outfeed conveyor at the exit of the pad conveyor systemthat is designed to move the pads (e.g., just ready to be separated padsor just now separated bags at the downstream end of the confiningmolding sections of the pad formation assembly) away at a speed greaterthan that of the bags in the bag web when traveling through the conveyormolding system (e.g., 1.25 to 2 times faster) and/or with theabove-described common corrugated grip arrangement as in replacement ofa simple bearing roller set with a corrugated conveyor belt whichmeasures with the formed pad configuration.

Utilization of an outfeed device provides for movement of the cut bagsmore rapidly away from the upstream web thus creating a tensioned, easyto cut gap between the to-be-cut/separated bag and the end of the web aswell as a quick movement of a cut/separated bag away from the cuttingregion.

Preferred is an outfeed device having an outfeed conveyor that moves theformed pad to a downstream reception component, if present, such as anoperator for (e.g., the pad to be put into immediate use) to anaccumulator bin, and/or to another conveyor system that transports it toanother area for immediate use or storage.

An embodiment also preferably features a cut or separation confirmationsensing system that also preferably has a photoelectric eye or similarsensing means as the above-noted cut positioning/timing sensor. Also,the cut confirmation sensing system also preferably has its sensingmeans mounted underneath the outfeed conveyor and suitably positionedfor detecting the gap between the cut bag and the end of the web,although multiple sensors and/or alternate positioning arrangements arefeatured under the present invention such as described above for the cutposition sensing system.

If this gap is not detected within a predetermined time period, thesystem assumes that there is a problem and shuts down (e.g., aninoperative or contaminated cutting heater wire as a source of a no webcut problem).

Also, depending on the sensing means utilized, a common sensor device(e.g., single sensor or integrated, communicating sensor set) can beused for a variety of the above described functions (e.g., determiningcutting timing and determining whether a cut and separation has actuallybeen achieved).

An embodiment also includes a “form feed” control device, whereupon at atime of conveyance stoppage, there is produced one or more unfilled bagsby the FIB bagger as to facilitate restart without having over expandedbags entering the conveyance system.

An embodiment includes all of the various features described above,although other embodiments of the present invention also include systemswith one or more (e.g., any one of the various sub-combinationspossible) of the various features described above for embodiments of thepresent invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a representation of a projection/recess in a convolutedconveyor element (with a sinusoidal or corrugated belt configurationshown, having a surface shape that preferably is also representative ofthe convoluted surface formation of a pad formed on the convolutedbelt).

FIG. 2 shows a cross-sectional view of a pad formed under the presentinvention with the illustrated embodiment comprising one flat facepositioned opposite a face having a corrugated or sinusoidal surfaceprofile with the grooves and projection shown in cross-sectionpreferably extending across the full face of the pad shown.

FIG. 3 shows a cross-sectional view of a conventional pad formed withopposing flat faces.

FIG. 4 shows an output zone of an embodiment of the pad formationassembly with a combination rigid platen and single conveyor pad chaindriving means as well as combination cutting mechanism timing sensingdevice and cutting mechanism.

FIG. 5 shows an input zone of a conventional pad formation assemblyreceiving completely formed bags from an upstream positioned FIB devicewith the filler material yet to fully cure.

FIG. 6 shows an input zone of a pad formation assembly embodimentreceiving completely formed bags from an upstream positioned FIB devicewith the filler material yet to fully cure.

FIG. 7 shows an output zone of a pad formation assembly embodimentsimilar to that of FIG. 4 but with an added outfeed device receivingseparated bags from the upstream bag confining-conveyance section.

FIG. 8 shows a view of a pad formation system embodiment.

FIG. 9 shows a view of a pad formation assembly embodiment with sidecovers removed to show the bottom conveyor, the top, non-moving platen,and parts of the cutting system for this embodiment as well as aproduced and separated pad from a pad chain.

FIG. 10 shows a perspective outfeed device end view of the assemblyshown in FIG. 9 but from the opposite side.

FIG. 11 provides a schematic example of features of an operationalcontrol system embodiment.

DETAILED DESCRIPTION

With reference to FIG. 5 there is seen a conventional pad formationsystem 20 having FIB system 22 with a combination sealing and cuttingmechanism 24 used to both seal and cut to-be-completed bag 26A from thecompleted bag 26B (with the completed bag containing, for example, mixedprecursor chemicals for polyurethane foam in a fluid, still in an earlycuring stage). In situations where edge seals are involved in the bagformation the edge seals are formed within the FIB housing with an edgesealer (not shown) positioned upstream of the end sealer 24 shown. Thus,each bag generated by bag making module 23 of the FIB system 22 is cutfrom the upstream film webbing (with C-fold webbing, two independentsheets webbing, slit tube webbing being examples of film webbingconventionally fed though an FIB system) at the exit zone at the bottomof the bag making module 23.

As further seen from FIG. 5, after the cut, the separated bag 26B dropsfrom the bag making module 23 of the FIB system 22 and is fed to theinput end 27A of the dual (top/bottom) moving conveyor assembly 27having conveyors 28, 30. FIG. 5 also shows the top conveyor 28 steppedinward to a certain degree to facilitate capture of the separated bag,but as mentioned above an operator (not shown) assists in thetransference to the conventional dual moving conveyor assembly 27 of aflat cushion formation system 20, since a “foam up” can be anticipatedif the system is left unattended. In a vertically oriented conventionalconveyor set there is not present such a step-in, but as with ahorizontal conventional conveyor a vertical conventional conveyorpresents “foam-up” issues.

Between the moving conveyors 28 and 30 there is further illustrated bags26C and 26D being carried by the moving conveyor system 27 as, in theillustrated system, the foam material expands and travels toward a“closer to being” or “at cured” state as it moves along within theconfines of the above and below moving conveyors shown.

With reference to FIG. 6 there is seen an embodiment of pad formationsystem 40 of the present invention shown as an embodiment having padenclosure formation device 42 as in the illustrated bag making means inthe form of an FIB system like that of U.S. Pat. No. 7,331,542 whichincludes bag making module 43 with an end sealing (non-cutting) bagsealing mechanism 44 set up (e.g., altered) to seal but not cut theto-be-completed bag 46A from the completed bag 46B. Thus, the bags beinggenerated by bag making module 43 are not cut from the film web at theexit zone at the bottom of the bag making module and there is thus fed acontinuous pad chain 46 (or bag chain in this embodiment) into the inputend 48 of pad formation assembly 50. Further, in a preferred embodiment,such as that shown in FIG. 6, all seals associated with the bag orenclosure (from which a pad is formed) are completed to the extentdesired upon departure of the pads from the FIB device (e.g. in someinstances a discontinued seal region is used for venting if the fillermaterial releases gas as in a foam precursor mix, but this venting sealdiscontinuance is typically a minor percentage of an overall seal inrecognition of the confinement function requirement of the seal). In theFIG. 6 embodiment web length of the bag chain 46 is shown as beingcontinuous at least within the pad formation assembly, as in acontinuous bag chain generated during the full operation cycle of thepad formation system. That is, if no undesired interruption occurs(which interruptions are more commonly involved in the prior artsystems), as long as the pad enclosure formation system operates, thebag chain will be continuously fed into the conveyor assembly 50. At,for example, the output end of the pad formation assembly, individuallyformed bags can then be separated, or a desired predetermined set offormed bags (bag chain sub-sets) can be separated from the remainder ofthe bag chain being fed to the output end. Further, there is preferablyalso implemented, via suitable control means, means for implementing anintentional discontinuance of bag chain feeding as in an implementedstop by the operator for switching of bag width size or a switch out toa new supply roll of bag formation film. Alternatively, anintended-predesignated length bag chain can be generated, as in a logiccontrol with operator board or the like to input operator desired bagchain length values (as some examples or operator controlled bag chainlength implementation).

As further seen from FIG. 6, bag 46C is shown as an intermediate bagrelative to a chain of bags including bags 46A, 46B (upstream) and bags46D,46E, 46F (downstream). FIG. 6 also shows the bag chain having acurvature generally lying above (or only a limited extent below) thebottom surface of bottom conveyor 52 (as opposed to a large droop 114 inthe bag chain (described below) as the chain of bags leaves the bagmaking module and is fed into the input end 48 of the dual (top/bottom)moving conveyor components 52, 54. Also, as seen the bags entering theinlet 48 of the conveyors have pre-established the required seals (e.g.,the formation of end seals and edge seal(s) having been alreadypreformed upon the respective, just formed bag first contacting theconveyance assembly (as in complete formation of the seals prior tobreaking the plane of the most upstream end of the conveyance assemblyand/or having the seals completely formed at a location closer to adispenser foam output location into the bag than the inlet end of theconveyance assembly and/or the most upstream end of the conveyanceassembly—viewed another way, the bag can be considered in one embodimentof the present invention as having all seals formed upon departure fromthe FIB bagger as in the FIB bagger supporting the sealing structure andfiller material dispenser structure on a common support platform whichsupport platform is also preferably releasably detached to theconveyance assembly or pad formation assembly and with the dispenser andsealing structure preferably being under a common housing of the FIBbagger (as shown)).

FIG. 6 further shows an embodiment of pad formation system 40 comprisingfirst and second moving conveyor components 52, 54 of conveyanceassembly 53. Alternate conveyance assembly designs are also featuredunder the present invention as in, for example, only one moving conveyorcomponent and a non-moving pad thickness conformance extension as asecond “conveyor component” (e.g., a smooth, low friction solid platenof the conveyance assembly). FIG. 6 also shows a conveyance assemblyarrangement wherein there is an above/below conveyor component set (52,54) with the illustrated bottom or first conveyor component 52 havingthe non-flat conveyance surface and the top or second conveyor component54 having a flat, non-convoluted surface for providing a flat surface inthe pads such as pad 46F shown passing through the pad formationassembly 50. Conveyance assembly 53 can represent alone the belowdescribed pad formation assembly 50 or a sub-assembly thereof, as whenthere is added, for example, the below described outfeed conveyancedevice 98 added sub-assembly, such that the pad formation assembly 50comprises conveyance assembly 53 together with the outfeed conveyancedevice 98 in an alternate embodiment.

Pad formation system 40 preferably comprises a foam in bag generationmeans such as the above noted FIB system together with pad formationassembly 50 (inclusive or exclusive of an outfeed conveyance device).Also, as seen from FIG. 6, the embodiment has the pad or bag sealscompletely formed by the filler (e.g., foam) in bag generation meanssuch that upon the bag chain being received at the inlet end of theconveyance assembly the bag formation itself is complete although padformation is not yet finalized for those filler material types involvingexpanding material.

Alternate conveyance assembly embodiments, in addition to the abovedescribed parallel moving and horizontal, parallel conveyor belt setarrangement, include, for example, conveyor sets arranged in an inclinedorientation or a vertical orientation. Also, the conveyor belts orcomponents (e.g., 52, 54) of the conveyance assembly are preferablyarranged parallel to one another although one or both may be inclinedrelative to the other in alternative embodiments as in less than a 5degree inclined in one or both to achieve, for example, a more openentrance and a narrower spacing downstream of the opening). Further, theconveyor components of the conveyance assembly can include a straightline incline arrangement or a multi-line incline set up as in a slopedinfeed and a non-sloped downstream section in one or both of theconveyor components (not shown).

Further, the reference to the conveyor components is in reference in oneembodiment to a continuous length structure from infeed to outfeed endwith the length being governed by the anticipated cure rates of the padsbeing formed such that they can retain their shape to a suitable extentby the time they depart the output end of the conveyance assembly.Examples of continuous length conveyor components include a single loopconveyor belt(s) or single loop conveyor belt with opposing solidplaten, although alternate embodiments of the invention for either orboth of the conveyor components are featured under the presentinvention. This includes, for example, conveyor loop sub-sets as inmulti-loop conveyors arranged in series or adjacent individual rollersas a non-loop or solid body roller sets as the “conveyor component”.These sub-set combinations can include, for example, relatively inclinedarrangements as well and still be “continuous” even with gapstherebetween (e.g., a first conveyance component section (e.g., conveyorloop) conveyor section at an obtuse angle relative to a second conveyorcomponent section (e.g., loop)) conveyor.

There is also preferably featured a conveyance assembly that isessentially in a non-stepped end arrangement as in the illustratedsecond conveyor component 54 (upper) which is not stepped inward oroutward relative to the first conveyor component (unlike system 20having the upper conveyor stepped inward to a certain degree tofacilitate capture of the separated bags into the conveyor set). Rather,as shown in FIG. 6, the input ends of the first and second conveyorcomponents are shown at about a common location (e.g., each flush to acommon plane or within less than 6 inches of that plane). Thisdifference is but one of many possible differences stemming from thenotion that, unlike the arrangement of FIG. 5, where a “foam up” can beanticipated if the system is left unattended, there is not the samelevel of concern for a foam up under an arrangement such as that shownin the FIG. 6 embodiment and thus operator assistance can be avoided orlessened.

Further, FIG. 6 shows an embodiment of pad formation system 40 of thepresent invention, featuring two moving, single loop belt conveyors asthe conveyor components 52, 54 with one non-flat (e.g., non-planar)conveyor component 52 having pad contact surface 56, as in a surfacethat is convoluted such as a corrugated or sinusoidal pad contactconveyance surface. FIG. 6 also shows only one of the two conveyorcomponents having a non-flat surface although alternate embodimentsfeature both conveyor components having the same or similar convolutedpad contact/formation surfaces (e.g., both pad contact conveyorcomponent surfaces 56 being sinusoidal with different amplitudes orwavelength spacings and/or with flat intermediate spacings betweenconvolutions and/or with shifted convolution projections relative toeach other, or alternate pad formation (and preferably driving) contactmeans).

Under the present invention reference to the non-planar pad “contacting”surface 56 includes indirect and direct contact between the pad and themoving conveyor body (e.g., the pad's enclosure material such as plasticfilm material being in direct contact with an exposed surface of aconveyor belt (e.g., a monolithic convoluted belt or a conveyor belthaving a base with added projections supported by the base as in a baseformed of a continuous sheet of material or a non-continuous base as ina chain-link base structure). The conveyor base is preferably in drivingengagement (or driven supported engagement) with a belt driver assemblyor belt support assembly S (FIG. 9) featuring a bracket connection Bbetween the outer frame structure F and conveyor side casing C (one oftwo shown) having suitable gearing and belt engagers extendingtherebetween and in connection with a driving motor (not shown) toachieve movement of the illustrated corrugated belt pad.

“Contact” between the convoluted conveyor component and the pad alsoentails indirect contact via one or more intermediate members as in anadded intermediate belt or protective liner layer whether integrallyjoined with a conveyor belt or moving independently relative to theconveyor belt or the like (e.g., a plastic protective sheet rollout-roll up arrangement at opposite ends of the conveyor assembly). Inan alternative embodiment, one or more protective film sheets are fedtogether with the bag chain web between the belt and bag surface,although with a lowering of foam-up potential, such protective film(s)are considered unnecessary for most applications.

While there are advantages in having the bag chain web driven by atleast one, if not two, opposed convoluted pad driving belts, alternateembodiments of the present invention feature one non-driving convolutedbut movably supported (e.g., passively driven) conveyor belt and anotherconvoluted driving conveyor belt or non-corrugated driving belt. Again,however, an arrangement where there is a non-flat or convoluted paddriving conveyor component and plus, for example, (i) a flat panel(fixed or driven or also a driving (e.g., reciprocating panel)conveyance component), (ii) a second, flat conveyor component that is adriving conveyor component or a passively driven conveyor component asthe conveyor component (e.g., a flat belt conveyor); or (iii) a second,non-flat driven or driving conveyor component (e.g., a duplicateconvoluted conveyor belt) are representative of alternate embodiments ofthe present invention. For example, one or both conveyor components canfeature a conveyor belt with a non-flat contact surface and also oneconveyor can be eliminated if the main conveyor has a corrugated belt infavor of a fixed platen for the second conveyor component in theconveyor assembly.

Such arrangements are unlike conventional pad formation designs whereinflat foam cushion molders feature two conveyors, each with a flat beltsuch that the cushions manufactured on these conventional systems havetwo flat and parallel faces. Accordingly, the present invention providesfor a different pad design (e.g., a different pad design as in a foam,such as a polyurethane foam, protective cushion pad) having one flatside and one non-flat side as in a sinusoidal or corrugated surface asthe convoluted surface. FIG. 1 shows a schematic view of a corrugatedbelt profile that is illustrative of a preferred non-flat or convolutedsurface profile for one (or two opposing) conveyor components in padformation system 40 featured under the present invention and shown inFIG. 6.

The corrugated profile 56 of the conveyor assembly is designed toprovide pads with a corresponding convoluted surface as represented byconvoluted surface 74 in pad 70 shown in FIG. 2. This convoluted surfacein the pad produced provides a pad with improved flexibility as in aflexibility level that enables a cured foam pad to bend around cornersor to better conform to the shape of an object (e.g., bend about acurved surface or a polygonal side wall set of a cushioned object and/orthe container itself and/or to fit or better fit upon folding into thecorner of a container and/or hold in position a corner edge of anobject). The design of the non-flat surface (e.g., projection and recessarrangement inclusive of size and/or shape of the respective projectionsand recesses of the non-planar conveyor component of the conveyorassembly) is designed to exceed the flexibility level of conventionalflat cushions having a common maximum upper surface/lower surfacethickness over their cushion support area. For example, flat foam (e.g.,polyurethane) cushions tend to be fairly rigid and usually buckle whenbent at extreme angles—such as a bend over 30 degrees. Thus, with thearrangement of the present invention, there is achieved non-damagingflexibility in excess of a 30 degree bend and preferably up to a 90degree bend (with the noted bend angles inclusive of acute angleformation on either side as in bending one way (acute side) and back theother way (acute angle now opposite the original and now obtuse side ofthe pad)). In other words, the pad design of the present invention (asin a corrugated or sinusoidal surface) is designed to more readily bendand/or fold without buckling or at least avoiding significant (e.g.,potential cushion function degrading or degradation of the enclosuresurface as in bag rippage) impact on the foam at the bend line or bendline region. This is facilitated with smooth contouring to avoid morereadily abutting projections upon bending as in the sinusoidalprojection pad surface in pad 70. Also, this flexibility feature isgoverned to some extent by projection and/or groove depth as a minorsurface convolution would not generate a lot of flexibility potential inthe produced pad (e.g., a greater than 50% valley depth relative tomaximum cushioning thickness height being an embodiment of theinvention).

In this regard, reference is made to FIGS. 1, 2 and 3 with FIG. 1illustrating in schematic fashion a non-flat conveyor component 52 ofconveyor components of pad formation assembly 50, which is preferably adriving component of the conveyor assembly, but can also, lesspreferably, be a driven component of the conveyor assembly. FIG. 2 showsa cross-sectional view of a pad formed under the present invention withthe illustrated embodiment comprising one flat face (e.g., a cushionfunctioning face) positioned opposite a face having a corrugated orsinusoidal surface profile 74. For comparison, FIG. 3 shows across-sectional view of a conventional pad formed with opposing flatfaces. Further, FIG. 2 shows tapered ends which illustrate the taperdown to a connecting web section that has since been cut or otherwiseseparated from the bag chain.

FIG. 1 shows a section of a conveyor component (using conveyor component52 as an example), having a base floor surface 58 (e.g., the interiorside of a conveyor belt loop) and a base region 60 (e.g., a base regioncomprised of a continuous sheet belt base formed of a layer of materialproviding sufficient tension strength to the base (e.g., a flexiblesheet of suitable conveyor material as in one with a limiting degree oftension stretching and sufficient flexibility to conform to a belt loopconfiguration)). Extending up from the base region is a series ofprojections 62 with recesses 64 therebetween with the projections 62shown in repeating sequence, which sequence preferably extends over thefull length of a conveyor loop (e.g., all but a conveyor sheetconnection location if portions of the projection/recess themselves arenot interconnected to complete the loop), although alternate embodimentsof the invention are featured including a convoluted pad contact surfacefeaturing one or more non-convolution surface areas separated by one ormore convoluted areas, or alternate projection recess areas as well aspossible variations along the length as in repeating sequences ofalternate height projections (e.g., high-low-high-low orhigh-med-low-high-med-low projections, or more random variations as someexamples). Also, an embodiment of the invention has the projectionshaving an axis of elongation that runs perpendicular to a direction ofconveyor travel as to provide a tread-like gripping function.

In the schematic depiction in FIG. 1, there is illustrated a monolithicarrangement in the corrugated conveyor component wherein the projectionis an integrated part with the base (e.g., a non-laminated common orcomposite material conveyor belt with integrated, monolithic base andprojection combination). Alternate arrangements under the presentinvention feature projections that are independent and integrated innon-monolithic fashion with the base as in projections that are adheredor mechanically fastened or heat bonded, or secured by alternatesecurement means to the base). Also, with the appropriate recessconfiguration (e.g., base thickness and/or wavelength in theprojections), the projections can be formed of a relatively rigidmaterial (e.g., generally non-flexible in the path of conveyance) withthe spacing therebetween provided by the recesses providing for loopconformance in this embodiment. In addition, under the present inventionthe base is formed of a continuous surface loop sheet, or as analternate embodiment, as a non-continuous surface base component as in abelt structure such as one made of plastic or metal links with theamount of non-continuous openings in that base being based on the notionof providing sufficient pad contact to achieve a desired level of padformation functioning implementation (via the contact surfaces in theprojections and preferably also the contact surface of recesses providedin the base (e.g., pad contact surfaces provided by base via linksurfaces)). It is noted that in some instances, as in high strengthenclosure material, there can be utilized a relatively open conveyorcomponent surface base (e.g., a majority or more open) with thetensioned, higher strength enclosure material generally functioning as acontinuation of the actual limiting conveyor component surface. However,a preferred embodiment for forming foam cushions within thin sheetplastic film enclosures is one having a continuous convoluted conveyorsurface in contact with the enclosure material (e.g., solid belt withoutany openings in the belt contact surface).

FIG. 1 also shows conveyor profile surface 56 having wavelength W (witha most preferred distance being about 1.5 inches with a range of 0.5 to5.0 inches and more preferably 1.0 to 2.0 inches being illustrative ofwavelength embodiments or distance between maximum peak to peak pointsin adjacent projections (and also preferably a similar distance frommaximum depth point to maximum depth point relative to adjacentrecesses). The overall height of the conveyor component 52 is also shownas H (with a most preferred height also being represented by 0.45 incheswith a range of 0.3 to 2.0 inches and more preferably 0.4 to 1.5 inchesbeing illustrative of preferred conveyor component height H). Theprojection height or amplitude “A” of the projections 62 of conveyorcomponent 52 is also shown in FIG. 1 (with a most preferred height being0.350 inches with a range of 0.2 to 1.8 inches and more preferably 0.3to 0.8 inches being illustrative of preferred projection height A).Also, the projection height preferably matches the recess depth in thepreferred embodiments featuring a sinusoidal or corrugated (e.g., allcurve and/or partial curve and/or in stepped or multi-stepped orstraight side walled projections). The base height “BA” thus equals thedifference of H minus A. Further, when a preferred sinusoidal pattern isutilized having smoothly curving contouring over the entire surface, thecurvature dimension “R” is most preferably 0.5 with a range of 0.25 to0.75 being illustrative of alternate embodiments. The recess depth tomaximum height of pad ratio is preferably 50 to 95%, more preferably 60to 90% with a value of about 80% being most preferred. Preferably theconveyor belt is formed of a solid or monolithic rubber body or acomposite of rubber and suitable strength enhancing filaments or webbing(natural fiber, or man made fiber as in plastic fiber and/or metal wirefilaments embedded for extra strength in the conveyor belt). Also, FIG.9 illustrates base material 60 being suitably flexible to handle arelatively small radius return curve RC (FIG. 9) as in one thatrepresents a ratio of 20 to 100 to 1 to conveyor length.

FIG. 7 illustrates an alternate embodiment of the present inventioncomprising pad formation system 65 with pad formation assembly 66 havingconveyance assembly 67. As shown in FIG. 7, conveyance assembly 67 hasonly one driving (and preferably also only one moving) conveyorcomponent 68 amongst conveyor components 68 and 69 used in pad formationfollowing bag chain feed to the conveyor assembly from a pad formationdevice (not shown in FIG. 7 but can be one such as FIB system 42 shownin FIG. 6). Conveyance assembly 67 is shown with conveyor component 68having a corrugated or sinusoidal surface 56 as in the earlierembodiment. This corrugated or sinusoidal surface 56 allows for thepresent invention to run with only one conveyor. Also, the secondconveyor component 69 is preferably represented by a less-convoluted ornon-convoluted (preferably flat or at least less convoluted then theother conveyor component 68) conveyor component as in a non-moving, flatplaten conveyor component (e.g., a metal platen suitable for handlingthe above described forces associated with an expanding and curing foamcushion pad). This platen preferably comes in direct contact with thepads as opposed to a conventional conveyer belt with panel backing platefor support. The ability to provide a more simplified conveyance systemas in one having a non-moving and non-convoluted conveyor component asone of the two conveyor components is facilitated by the opposite,convoluted driving conveyor component's design. That is, corrugatedconveyor component 68 with its corrugated pad contact surface easilypulls both the pad itself as well as other pads in the bag chain throughthe molding zone despite only one driving conveyor component (e.g., azone extending along a portion or all of the conveyor assemblypassageway 71 formed between the conveyor components regardless of theirrelative orientation as a set (such as horizontal or vertical setorientation) or to each other (such as relative inclines in the setcomponents)). Also, due to the characteristics associated with certaintypes of pad formation, such as expanding foam cushion pad formation,the use of a flat conveyor belt in a single moving conveyor componentconveyance assembly (e.g., a platen and flat conveyor belt loopcombination) is considered by the Applicants to lack a drive arrangementthat can suitably move the cushions because of the high drag forcesinvolved and the typical slippage (coefficient of friction) potentialassociated with pad enclosure material utilized.

With reference to FIGS. 2 and 3 there is seen in FIG. 2 a pad (foamcushion pad) 70 formed by an embodiment of the present invention, whilein FIG. 3 there is seen a pad (foam cushion pad) 72 formed by aconventional system such as shown in FIG. 5. As seen pad 70 features acorrugated conveyor component contact surface 74 which, in theillustrated embodiment, is the lower surface of the pad, whichconfiguration would occur, for example, in a conveyor assembly such asshown in FIG. 7 wherein the pad being fed through passageway 71 is beingdriven by conveyor component 68 which, in that embodiment, is shownlying below the pad chain shown as including pads 46G, 46H as well as aseparated pad 461. Thus the corrugated conveyor's contact surface 56 isplaced in contact was the pad chain or bag chain web and the surface 56shape is imparted to the pad being formed as the representative bagcures while traveling between the conveyor components. Also, the patternformed in the pad preferably essentially conforms to the pattern of thenon-planar conveyor component such that the wavelength W for theconveyor belt corresponds to wavelength WC for the pad.

Also, in a conveyance assembly that has a pair of moving, non-planarconveyor components, there would be formed a pad having a similarsurface configuration on both exposure/contact sides of that pad if theconveyor components have a similar non-flat contact surface (or therewould be formed different non-flat configurations if the relativeconveyor components have different contact surface shapes or projectionsthat are not arranged in one-to-one projection alignment). In use as acushion pad, the corrugated side can either be placed in contact with anobject being cushioned and the non-corrugated side in contact with acontaining member as in a container (e.g., box), or outer wrapping(e.g., shrink wrap) or the like in which the object is placed or viceversa.

Also, in lieu of a sinusoidal contact surface formation in the pad, awide variety of other surface configurations are also readily achievableunder the system of the present invention as in fabricating conveyorbelts with alternate surface profiles. For example, the surface of thenon-flat conveyor belt need not have a regular cross section withexamples (not shown) found in pads with a mix of flat and sinusoidalsections. Another option is to make a convoluted surface that has asinusoidal profile in both directions. Further, while a preferredembodiment has the projections extending for a full conveyor componentwidth, alternate embodiments feature projection strip(s) of suitablewidth(s) to achieve the desired drive through function of the bag chainweb and also preferably the formation of a suitable convoluted surfaceprofile in the formed pads not extending continuously the full widthwith end-to-end openings. Depending on the width(s) of thenon-convolution areas between projection strips this arrangement canlessen the flexibility in the bag and thus is less desired in most usageenvironments of the present invention.

The preferred filling material fed to the enclosure bag is apolyurethane as in one fed into a bag being formed with a polyurethanedispensing system with polyol and isocyanate “A and B-side” chemicalfeed lines feeding to a mixing dispenser chamber of a dispenser of thedispensing system.

As seen from FIGS. 4, and 7 to 9 there is provided a pad web separatoror separation means 76 with an embodiment of a suitable separation meansbeing a mechanical, heated wire cutter mechanism although a variety ofother separation means are featured including a perforator upstream withdownstream pull off device combination, an energy or material applier asin a laser beam, non-contact heat applier, a fluid cutter, or the like.Pad web separator 76 is preferably provided downstream of the receptionentrance of the pad conveyance system (e.g., 53 of FIG. 6 or 67 of FIG.7) and more preferably at or close to (e.g., just downstream as in lessthan a foot) of an output end of at least one conveyor component as inthe output end of the conveyance assembly in general. That is, in apreferred embodiment of the present invention, cutting and separation ofeach bag from the film web is done at the output zone of the conveyancesystem and thus is different than conventional conveyance systems withflat foam cushion molding systems wherein the bags are cut and separatedfrom the film web right at the output zone of the bagger in exactly thesame manner as with a standard FIB system. This means that under theseconventional system the bags are separate entities as they enter andmove between the flat cushion forming conveyors as shown in FIG. 5.

In a preferred embodiment of the present invention, the separation(e.g., cutting) operation is moved away from the output zone of thebagger and put closer to the output zone (e.g., at or near the outputzone) of the conveyor system. This means that the film web is preferablyuncut (or preferably not fully cut as with upstream perforations) untilit exits the conveyance system (e.g., exits the conveyor belt(s)). Underthe preferred arrangement of the present invention, the pad chainwebbing (e.g., bag chain webbing), which webbing is present betweenadjacent pad main bodies, is maintained intact through the conveyancesystem which has shown to help keep the pads from slipping out ofposition. Whenever pads slip or slide out of their proper positions jamups can occur which may lead to foam-ups and subsequent damage to theFIB system, the pad molder, and the work area around the machines. Undera preferred arrangement of the present invention, with the pad web leftintact during travel through the conveyance system, there is lessenedthe possibility of bags catching and folding on their way into theconveyor gap.

With reference particularly to FIGS. 4, 7 and 8 there is seen a sensingdevice or sensing means 78 as in a microswitch based sensing device. Asseen from FIG. 4, a sensing device 78 is one that has an adjustablecontact member 80 that can ride up and down with the surface of the padweb traveling in the conveyance system to trigger microswitch 82 at theappropriate time to initiate a subsequent action as in operation ofseparation device or means 76 (immediately or a logic control timesequence based on pertinent variables such as pad chain travel speed,relative spacing between the sensing device trigger point (time and/orlocation) and the separation means, as well as the action timeassociated with the separation means). Microswitch 82 is further shownin FIG. 4 as having an extension support 84 for properly positioningcontact member 80. Extension support 84 is shown secured to machinesupport frame-structure 86 which comprises an enclosure beam structureextending about the conveyance assembly and providing support for outerside covers 88 (see FIG. 10 for an example of such a cover). Alternatesensing means are also featured under the present invention as inoptical sensors (e.g., photoelectric sensors) with or without the use ofoptical demarcations (e.g. added print on the bag chain) or transversebag bond seal lines, and the like. In the illustrated embodiment of FIG.4, the sensing of the cut zone is done with a microswitch form of sensorthat is positioned a few inches (e.g., 2 to 12 inches) upstream of theseparation means or cutter mechanism 76 (shown as comprising cuttingjaws) and picks up the reduction in pad thickness between eachbag—created by the absence of foam between the seals—making that portionof the pad substantially thinner than the main portions of the bag chain“web”. With the use of such a sensor means there is preferably featuredone convoluted side and one non-convoluted side in the pads being formedwith the contact 80 riding on the flat or less convoluted side;although, with appropriate depth/rise setting differentials to triggerthe microswitch activity, the contact can be made to run along aconvoluted side as in a pad having both elongated sides withcorrugations (the seal webbing preferably being thinner than the basesection below the recesses).

An embodiment of the present invention features a pad molder havingseparation device 76 in the form of a cutter mechanism that operatesheating mechanism (e.g., cut wire 90) based on a monitored, constantpower operation, which utilizes, for example, temperature controller 92shown in FIG. 4 (e.g., a device that monitors the wire temperature witha temperature sensor and then adjusts power being fed to the resistancewire or alternate heater means based on a feed-back loop or a nonfeed-back loop arrangement that just sets a desired constant temperaturewithout feedback monitoring). In this regard, reference is made to theaforementioned, incorporated by reference, U.S. Pat. No. 7,331,542 aswell as U.S. Publication No. 2005010323 which is also incorporatedherein by reference and which describe a feedback wire monitoring systemin a different setting.

In another embodiment, heating mechanism 90 is maintained at constantpower all the time and thus without the need for the above-notedfeedback monitoring system (e.g., at least all the time the padformation system is turned on or powered up, whether in an idle oroperating mode, and preferably also when the pad formation system is ina “sleep” mode period wherein the pad formation system, following anextended period of non-use, is automatically placed into a sleep modewhen not having been used or timely shut down by the operator as in for10 minutes or more). Under such a constant power system, there is nofeedback loop and thus no need for a means to sense or measure wiretemperature. The resistance heater wire (or like heating mechanism)heating system is supplied with a constant wattage which can be manuallyadjusted to a desired setting and left there to achieve an optimal andconsistent cutting temperature. This alleviates the additionallimitations associated with the above-described feedback monitoredheating system in that with preferred thin wire heating element sizesthere is introduced sensing difficulties arise (e.g., the above-notedfeedback monitoring system utilizes the change in wire resistance versustemperature as a means of measuring wire temperature which isproblematic for some wire types).

Also, in the constant temperature (non-feedback) heating systempreferably even during sleep mode (where the power to the various padformation system's sub-systems is minimized or shut off) the power tothe cutter wire is still maintained. Under the above-noted constantpower system for heating wire 90 without the monitoring featuresdescribed above, there is utilized an open loop arrangement. In both themonitored and a less or non-monitored constant power system, the cutterwire temperature achieved is preferably designed to be at about therelevant enclosure material's melt point or somewhat above, but not toofar above as to generate undesired melt build up on the wire.Accordingly, in this embodiment cutter wire 90 is powered up, whether itis cutting or whether it is in idle mode as long as a power source isavailable for achieving such a powering up (direct or back up powersource). Also, with proper adjustment of the input voltage to the wirevia control means 92, cutter wire 90 is maintained at close to its idealcutting temperature at all times.

With this arrangement, cutter wire 92 requires much less cleaning thanwith standard FIB cut wire controls. For example, cut wires notmaintained at a sufficient melt cut temperature can collect a buildup ofpreviously molten, partially burned, and fully carbonized plastic overtime. This buildup is minimized according to a constant temperatureembodiment of the invention by ensuring that the wire 90 does not dropbelow the minimum temperature required to cut the film. Keeping the cutwire hot at all times—also prevents the molten plastic from “freezing’onto the cut wire as it cools between cut cycles. This also helps tominimize buildup on the wire to reduce maintenance and increase lifespan. Furthermore, on previous FIB based pad molding systems, the cutwire typically ran off of impulse power control. With impulse power, itis difficult, if not impossible, to control the wire temperature asaccurately as with the constant power approach. This leads toovershooting of the ideal cutting temperature, and subsequent burning ofthe plastic. It also means that the molten plastic has a chance to“freeze” onto the cut wire as it cools between cutting cycles. Thus,under a preferred embodiment of the invention the cutter wire isprecluded from either dropping too far below a predetermined desiredtemperature or rising above that predetermined temperature (e.g., thecutter wire is prevented from dripping or exceeding the desiredtemperature (e.g., the melt temperature of the film material of theenclosure) within −±20° F. and more preferably ±5° F. and even morepreferably ±2° F. and less) during usage and idle periods and preferablyas well during a sleep period, if applicable.

Maintaining the heated wire at a constant, predetermined heattemperature also imparts a much longer life span for the cut wire, thanon conventional FIB systems and on all previous pad molding machines.For example, under this embodiment of the invention, wire life isextended because the wire temperature is fairly constant at all times.On a typical FIB cut wire system, as one where the wire operates onimpulse sealing control, the wire's temperature changes from roomtemperature to cutting temperature within milliseconds. This rapid andfrequent temperature cycling causes mechanical stresses in the wire andits terminals, which eventually lead to failure. Maintaining the wire ata relatively constant temperature in accordance with the presentinvention's arrangement and technique minimizes these thermally inducedmechanical stress failure mechanisms. This technique requires more powerinput to the system and also has the disadvantage of keeping the cutwire at a relatively high temp at all times and thus added operatorcontact care needs to be taken and thus this approach was considered tohave been avoided in the noted conventional systems.

Furthermore, under a preferred embodiment of the present invention, thebag making cycle of the FIB system is activated every time the padformation system molder makes a cut cycle. Again, there is preferablyachieved with a suitable controller sub-system as controller sub-system91 (e.g., a microprocessor and/or logic board) or a plurality ofdesignated controllers working together, with an example of a controlsystem for an FIB system being described in the aforementioned U.S.Publication No. 2005010323 to IntelliPack, Inc. and entitled OperationalControl System And A System Providing For Remote Monitoring Of AManufacturing Device which is incorporated herein by reference. Theactivation of the FIB system to dispense another pad of the pad chain inresponse to a cut cycle (e.g., the activation of a cutter (or separationmeans) or the triggering event can be the activation and/or confirmationof a cut by the separation sensor described below) keeps the two systems(the FIB system and the pad formation assembly) operating in sync; andprevents the bag making module from producing bags faster than theconveyor assembly take them in. The synchronous operation prevent theconveyor assembly from running too fast, which can, if allowed, pullfilm through the FIB mechanism at an undesired rate which can createextensive problems with the bag making process.

With reference to FIG. 7, there is further seen that the top and bottomconveyor components 68, 69 are arranged such that formed bag 46H isfurther conveyed outward past the pad formation assembly and pick up byoutfeed device 98. Outfeed device 98 is preferably in the form of anoutfeed roller conveyor that also supports the output pad at a time ofweb separation or cutting. For example, in one embodiment the bag to becut away is supported on the roller conveyor while the seal webbing ispositioned in as to be bridging a gap formed between the output of theconveyor assembly and the upstream end of the outfeed roller conveyor98. In an alternate embodiment shown schematically in FIG. 7, outfeeddevice 98 is provided with a peak and valley convoluted surfacegenerally designed to conform in mirror fashion to the corrugatedsurface of the pad produced as to catch and position the separated padon the outfeed conveyor.

As further illustrated in FIGS. 4 and 7, sensing device 78 with contact80 and microswitch 82 is preferably mounted close (within one foot as in6 inches and more preferably within 3 to 5 inches upstream of the cuttermechanism) with cutting jaws 94 and 96. In this way, sensing device 78can pick up the gap between the seal of the leading pad 100 and the seal102 of the trailing pad. In other words, in a preferred embodiment ofthe invention there is featured means 97 for controlled cutting orseparating of two adjacent pads as in means featuring web positioningmonitoring means 78 in combination with web separation means 76. Also,separation gap expansion means SG shown as comprising control meansoperating as to coordinate with the separation means a timely adifferential relative travel speeds between the travel speed of the padbeing separated and the travel speed of the next in line bag in the bagchain web). For example, the separation gap expansion system preferablyfeatures a speed signal generator to establish a desired roller drivingspeed in one or more drive rollers of the roller conveyor and/or a speedsignal generator designed to maintain an outfeed conveyor roller driverate that is consistently above the chain bag web travel speed totension the area being separated (if speed up timing is active justprior to separation) in the seal webbing area which facilitates bagseparation and also preferably the higher speed roller in the outfeedroller conveyor moving the separated bag in accelerated fashion awayfrom the cutting region. An alternative of the separation gap expansionmeans features an upstream braking and downstream speed re-initiationcontrol means with associated conveyor motor control as with the belowdescribed control system CS (FIG. 11).

In an embodiment, the seal webbing gap is formed between downstream andupstream seals 100 and 102 (relative to film travel direction) as toform an intermediate seal webbing section 104 that is preferably the cutlocation when the heated wire 90 comes in contact with the film passingby heat degradation avoidance resistance pad 106 provided at the end ofjaw 94 so as to compress and heat cut the same.

That is, in an embodiment, the FIB system (or alternate enclosureforming means) preferably forms a pair of separated seals (100, 102) asby way of a pair of spaced apart heated wires or strips heated to a seal(but not cut) temperature, with each seal of the pair positioned closerto a respective pad main body (e.g., expanded filler material) in thepad chain such that a thinner web sheet section or seal webbing section104 is formed between those two seals. Seal webbing section 104 ispreferably sized to properly receive the jaw compression surfaces 106and 108 in cutting jaws 94, 96 so as to avoid heated wire contact withpad filler material (e.g., foam) within the adjacent bags. Further,sensor device 78 is preferably designed to detect the thinner inthickness zone region between the bags 46H and 46G in the pad chain (andbetween the noted seal lines 100, 102). Preferably, this thinner zone103 is comprised solely of a laminate web sheet section without anyfiller material provided therebetween (e.g., a laminate web sheetsection formed by the two layers of an original C-fold film (gusseted ornon-gusseted) brought together and sealed along the free edge regionduring FIB processing).

The distance D is a distance that places cutter wire 90 (or alternateweb separation forming means) downstream of sensor device 78. Thedistance D between the sensor sensing location and the cut location isdesigned to accommodate the relative timing of the conveyance system'sconveyance of the web sheet section 104 (and pad chain stoppage time atthe determined location if applicable) and the timing requirements ofthe web separation forming means, as in the closing of the jaws 94, 96of the heated wire support and compression anvil with associatedadjustments (e.g., jaw start and/or closure rate) being made fordifferent length pads in the pad chain. The separation location betweenadjacent bags such as bags 46H and 46G is preferably right at about thecenter of sheet section 104 (±0.5 to 1 inches tolerance relative to truecenter positioning) although further deviation is also possible with apreference to avoid any type of seal degredation at seals 100 and 102 orcontact with a filled portion or main body of the pad. A preferreddistance for D is less than 12 inches with a range of 4 inches to 12inches being well suited for many embodiments of the invention. Thus, anembodiment takes into consideration the chain web travel speed betweenthe end points represented by distance D and the time it takes forcutter device 76 to be in an actual cut state (wire compressed againstweb material and anvil surface of adjacent jaw and temperature atdesired temperature level which is rendered easier by theabove-described constant temperature feature of the present invention asno heat up time delay need be factored in relative to the timing of thetime between sensor 78 triggering and placing the film webbing at thedesired location relative to the cutting jaws coming into their cutposition). This coordination as to web conveyance and placement of theseparation means at the proper time and location relative to that websection is carried out by a suitable control sub-system as in the belowdescribed separation or cut mechanism control sub-system SC of controlsystem CS (FIG. 11).

As shown in FIG. 4, in addition to distance D between cutting line “CU”and sensory location trigger line SL, there is also shown end plane lineEL at the end of the conveyor component (e.g. upper platen 69).Preferably length L1, between EL and CU lines (vertical planes when anabove/below conveyor assembly is utilized as shown in FIG. 4) is lessthan 2 feet and more preferably less than 1 foot (e.g., at or morepreferably less than a pad length as in 50 to 90% of the pad length)Accordingly, length L2 between sensor location trigger line SL and thedownstream end of a conveyor component is equal to L1−D and ispreferably less than 6 inches as in less than 25% of pad length.

As an operating example, sensor device 78, with contact 80 andmicroswitch 82, detects the gap 103, and the machine control systemactivates the moving jaws after, for example, a controlled time delay,if required, so that the jaws close on the film for cutting at the timecutter wire 90 is at the central point 104 or at least between seallines 100 and 102 of seal webbing as it comes into location between jaws94 and 96 at their point of cut contact.

In the embodiment shown in FIG. 4, both jaws 94 and 96 are preferablymoved, unlike a typical conventional FIB machine where one jaw is keptstationary, and the opposite jaw moves. Furthermore, in an embodiment ofthe invention, cutting jaws 94 and 96 are pneumatically driven whichprovides close control over timing, although they could be driven withelectric motors, electric solenoid actuators, with hydraulic cylinders,or with mechanical cams or alternate cutter operation positioning means.

Thus, in the FIG. 4 embodiment, moving jaws 94 and 96 travel toward thefilm web gap 103 until they contact and press against each other. Also,cutter wire 90, which is preferably mounted to the lower moving jaw(which supports the wire during the cutting process), moves into acompression cutting state relative to the opposite anvil surface 106 ofjaw 94 positioned to an opposite side of the bag chain. When the movingjaws close, the web is preferably cut completely through and the leadingbag 46H is separated from the moving web (unlike the seal formation 100and 102 where, for example, a sealing wire is retained at a temperaturesufficient to band plastic together but not cut through). Preferablycutter wire 90 is powered with a fixed and constant DC currentdetermined by a fixed voltage that is applied to the cutter wire 90 asthrough controller 92. In an alternate embodiment, separation means 76sufficiently weakens the connection (e.g., melt state, partial cuts,etc.) such that there can be achieved separation as with a speeddifferential provided by, for example, driven rollers of conveyor 98being driven at a sufficiently faster rate relative to the upstream,remaining pad chain (which can be either stationary or slower moving)and/or by reliance on a gripping state provided by outfeed conveyor 98.

Also, in an embodiment cut wire voltage is controlled via manualadjustment, and once a predetermined proper voltage setting is obtainedthe cutter wire temperature rarely needs adjustment. Thus, controlsystem CS preferably comprises heating mechanism control sub-system HCfor implementing the adjustable constant power setting. Control systemCS can take on various forms as in an internal microprocessor or linkedup computer with microprocessor and/or logic control board that ishardware and/or software based or alternate logic control means. Thevarious sub-systems also preferably feature respective logic controlmeans for carrying out the respective functions described herein As anexample, separation control sub-system SC preferably comprises asuitable logic processor component (component 93) for activatingsignaling device 95 which is in communication with the drivingcomponents associated with separation means 76 driver 97 (e.g.,pneumatic jaw pair driver) as to coordinate their respective motions.

Under this embodiment, accurate control of the heating elementtemperature while cutting film avoids the problems caused by overheatingthe cut wire, which include rapid carbon buildup on the wire (whichimpedes its cutting ability and necessitates cleaning) and shortenedwire life as described above. In addition, the arrangement of thepreferred embodiments of the present invention also avoids the problemof not cutting (when full cutting is desired), which results from underheating the cut wire.

In an embodiment, cut wire 90 is made of a material that is Nichromewith a solid round cross section, as in one which is approximately0.015″ in diameter. Nichrome material is preferred for this applicationbecause it has a very low TCR (Temperature Coefficient of Resistance),which means that the electrical resistance of the wire does notsubstantially change between room temperature and cuttingtemperature—which is approximately 400° F. for many preferred usage ofthe pad formation system. In this regard, reference is made to U.S. Pat.No. 7,213,383 issued May 8, 2007 of IntelliPack, Inc. of Tulsa, Okla.,USA which describes some heating and sealing wire arrangements and whichpatent is incorporated herein by reference. Also, the jaw supporting theheater wire preferably has a relatively hard Durit™ material on itsface, which the opposing jaw has a face 106 formed of Silicone rubber(e.g., 0.06 inches thick) with a hardness of about 60 durometer.Further, in the illustrated embodiment, after the cutting process iscomplete (this takes about two hundred milliseconds) the jaws move awayfrom the web back to their home positions, and wait for the next cutcycle command.

The arrangement of an embodiment of the present invention furtherprovides avoidance of problems associated with bag cutting features. Forexample, it is noted that the most frequent failure mode withconventional FIB systems is the failure to properly cut the bag from theupstream web. This leads to problems on conventional FIB applications.With pad molding being an attempted automated process in manyconventional systems, bad cuts can lead to disaster. As an example, foamups, jamming and other problems can arise if just one bag hangs up on acut wire and the bagger just keeps making more bags on top of it. Theseevents often create a mess of foam depending on how long it takes theoperator to notice that something is wrong.

Under an embodiment of the present invention with an output end of theconveyor cutting technique, the relatively common cutting failuresdescribed above are avoided. This avoidance of a cutting failure and/orfailure to timely detect a bad cut is avoided by, for example, the abovedescribed constant power cutting process which is more reliable than theabove-described impulse power with feedback monitoring method usedpreviously, such that the number of bad cuts is dramatically reduced. Inaddition, a bad cut at the end of the conveyor will avoid massivefoam-ups since the foam is already fully or nearly cured at that point.That is, a bag cut failure at the end of the conveyor is a much lesstrouble causing event than one at the output of the bag making modulewherein a filler may still be expanding as in liquid foam precursorbeing in a rapid expansion state.

An additional feature provided under an embodiment of the presentinvention includes means for achieving emergency stoppage of bagproduction as between an FIB system bag output and conveyance assemblyinfeed. A preferred sensing system for implementing emergency stoppagesystem 112 of the present invention is featured in FIG. 6. Emergencystoppage system 112 comprises sensing device 116 for detection ofexcessive bag droop 114. Sensing device 116 is shown in FIG. 6 ascomprising a photosensor device 117 strategically mounted on conveyorsupport frame structure 118 in an underlying positioning arrangement inthis embodiment. In the illustrated embodiment in FIG. 6, photosensordevice 117 is shown as a diffusor reflective photoeye sensor device.There is further illustrated in FIG. 6 a releasable locking assembly 120to help properly position the FIB system relative to the pad forwardingassembly. Locking assembly 120 is shown as comprising connection brace132 shown in this embodiment with opposite end releasable locks 124 and126 (e.g., an over center latch or key pin trailer hitch arrangement orbolt down arrangement or tool-less hand knob lock down connection oralternative locking means for precisely sealing and locking the relativeposition of FIB System 42 and conveyance assembly 53 (as well assupported sensor system 116) while still providing for ready separationand repositioning of servicing of the mobile FIB system 42 shown).

Photosensor device 112 detects bag chain web sag or droop between theoutput of the bagger and the input of the conveyor system. Current padmaking machines simply drop their bags so that they can be fed withmanual assistance, into the gap between the opposing conveyors. Asmentioned earlier, in a conventional system the bags are cut andseparated from the main web as they exit the bagger so they are separateentities from that point going forward as shown in FIG. 5, for example.Unlike those systems, an embodiment of the present invention works in adifferent manner with an advantage over previous methods as it helps toavoid exploding bags, foam-ups and pad jams that have beleagueredprevious conveyor based cushion molder designs.

The emergency stoppage system is shown with sensing device 116 (with its117 photoeye) mounted at a location suitable for differentiating betweena normal course of travel for the pad chain and a deviation in thatcourse of travel brought about by a disruption as in a downstream bagjam (e.g., a normal travel course may feature a 6 inch or less droopbelow the central horizontal plane located between the respectiveconveyance systems' components due to a curvature in going from theoutlet of the FIB to the conveyance system inlet, while a disruption(e.g., downstream jam) can result in a larger droop factor such as onegreater than 6 inches with, for example, about a foot or more under thenoted central horizontal input plane of the pad molding conveyors beinga generally suitable sensor location as it provides for minor deviationsin normal travel while timely picking up a large droop due to adisruption. More precise disruption detection positioning of less thanone foot is also possible, but the added spacing helps in the abovenoted regular travel deviation potential. As shown, sensing device 116preferably faces towards the FIB system, and is designed to pick up thefilm web if it droops into its sensing zone as illustrated by thedash-lined bag path 114. This system is also suited for alternateorientations of the conveyance system as a jam would lead to a deviation(e.g., a build up on one side or the other in a pad chain section in avertically oriented conveyance system which would occur upon bag jamsuch that a sensor (such as sensing device 116) positioned to each sidecan readily pick up a conveyance disruption).

When sensing device 116 does sense the presence of film, the FIB baggeris placed in a stop making bag mode and the conveyors are directed tostop moving based on information provided by pad chain jam sensorcontrol sub-system JC. An embodiment of the invention features a sensingdevice for use in detecting bag chain excessive droop that comprises adiffuse reflective type of photoeye which has two basic component partsbuilt into it, a light source or emitter and a light sensor orcollector. If the film web drops into the photoeye's sensing zone, somelight from the emitter will be reflected back towards the light sensor.When the amount of light received by the sensor reaches a pre-setthreshold level, the photoeye reacts by sending a low voltage signal tothe system controls. This halts the bag making process and also stopsthe motion of the conveyor system. Other types of presence ornon-presence detecting means are featured in U.S. Pub. No. 2009/0056286to Intellipack Inc. and which application is incorporated herein byreference.

In the embodiment shown, for example, in FIG. 6, the bagger and the padmolder are set up so that there is a moderate (e.g., five to six inches)droop or sag in the film web that is suspended between the output of thebagger and the input of the conveyors during normal operation. The webdroop/sag will increase if the bagger is making bags faster than theconveyor is producing pads and/or if the pad molding conveyors haveslowed or stopped completely—or if the microswitch controlled cuttingjaws are out of sync with the web of pads. If such bag web drooping andthe likely jam situation caused by that is not addressed and bagproduction is continued to be allowed, the foam filled bags coming outof the bagger may expand and cure to the point where they can no longerbe pulled into the conveyor without damaging the integrity of the bagsand/or causing a foam-up at the entry zone of the conveyor. On previouspad molders, the bagger had no way to sense if the conveyor has jammedor slowed down. The bagger will continue to make bags and since thesebags do not enter the conveyor they accumulate at the output zone of thebagger and they expand as normal, unrestricted bags. Eventually the FIBsystem will foam itself up, sometimes in a spectacular manner. Sensingsystem 116 helps to prevent problems if the bagger and the pad molderget out of synchronization. The bagger making module of the FIB systemcan be prevented from making an additional bag unless the conveyanceassembly is in a state that is ready to accept one. The emergency stopsystem or droop detection system 112 preferably is in communication witha processor pad chain jam sensor control sub-system JC with the droopdetection system 112 relaying an excessive droop status signal which isprocessed as to trigger an appropriate shut down in bag film feed forbag formation and material feed for bag feed and preferably also bagconveyance operation (with also preferably a visual and/or sound alarmdevice activated) (e.g., see alarm control sub-system AC and conveyancesystem control sub-system CC which interface with jam sensor controlsub-system JC).

An additional feature of an embodiment of the present invention includesa cut or separation status sensing system 130 best shown in FIG. 7.Sensing system 130 preferably includes a sensor device 132 as in aphotoeye that is used for detection of proper pad cutting at the outputend of the conveyor system. In this embodiment, sensor photoeye 132 ispositioned near the output end of the conveyor system and is alsopreferably mounted so that it looks up (or across depending on theconveyance set up) at a location downstream from the pad formationassembly conveyor end as in between either the end of the pad formationassembly conveyance system and a downstream support or betweencomponents of that downstream support structure. As an example there isprovided an outfeed conveyor 98 and a sensor which generates a sensorline that extends between two of the powered takeoff rollers of theoutfeed conveyor system at the exit end of the conveyor assembly. Forexample, in an embodiment, photoeye 132 operates as a cut status sensingsystem 130 wherein the photoeye senses the presence of pads or film asit looks up (or across depending on orientation of the conveyancesystem(s)). That is, when a pad is cut from the pad chain, a gap isformed between the bag and the downstream end of the remaining padchain. Also, with driven roller conveyor assembly 98 as the downstreamor outfeed pad support, the takeoff rollers are preferably run fasterthan the conveyor component(s) in the conveyance assembly. Thus, as thebag is cut while on the downstream support the “takeoff” rollers willmove the separated bag more quickly away from the upstream chain web,and a gap will form as the separated bag moves more rapidly away. Thephotoeye thus can sense the gap, as there is nothing above it to reflectits emitted light back to its sensor circuit (or some other form oftriggering sensor arrangement). If the pad formation system of thepresent invention is running normally the gap should be visible on aregular basis, and the gap should be detectable as every cut is made. Ifthe cuts are not being made, however, then no gap will be formed, andthe sensor will see the presence of film or pad material constantly.Upon such an occurrence, a signal will be generated by an appropriatelogic control means as in separation or cut confirmation controlsub-system SCN, and there is initiated a system shut down as in havingthe system pad formation system (FIB bagger and pad molder) beingdirected to shut down if at least one gap is missing. In an embodimentof the present invention, there is utilized a diffuse reflective type ofphotoeye for this application which is preferably of the same or similartype as previously discussed in regards to the web sag detection meansin emergency stoppage system 112.

As described above, there is featured in an embodiment of the inventiona sensor system for detecting bag droop and/or non-separate bagsdownstream of the conveyance assembly output. Thus, having a rigidmechanical connection between the FIB system and conveyance assembly ofthe present invention facilitates proper sensing system positioning.Examples of this form of connection is seen in FIGS. 6 and 8 which showa rigid mechanical connection assembly 132 (132′) provided between thebase of the FIB system and the mounting stand 118 for the conveyanceassembly. This rigid (but preferably releasable) connection alsomaintains the bagger in the optimum relative position with respect tothe conveyance assembly mechanism to insure proper feed of the bag webfrom the output of the bagger to the input of the conveyor moldingsystem.

An additional feature of an embodiment of the present invention residesin bag length and fill percentage adjustment system while the presentinvention is running. In this way the length and fill percentage of thebags can be adjusted, on the fly, without stopping the bag formation andconveyance assembly. This can be accomplished by using the standarddisplay and menu/adjust knob on the front of the bagger coupled togetherwith appropriate software or logic processing provided by control systemCS, which times the timing of the film feed being used to form the bagsin the web, the timing of the material feed as in the foam processorfeed and the timing of the sealing means for the bags in the bag chain(reference again being made to the aforementioned FIB control system ofIntelliPack, Inc. having a suitable system that is modified to meet theparameters of the present invention as in adding alternate orsupplemental logic control boards, etc.). There is thus provided, forexample, a suitable material fill rate relative to the time allotted forfilling in the bag formation and travel components in the bag makingmodule which are set in conformance as well with the requirementsassociated with the downstream pad formation assembly.

There is also featured under an embodiment of the present invention aform feed mode process and associated logic control means (which isrepresented as form feed control sub-system FF in FIG. 11 of controlsystem CS) which is provided in order to stop the present inventionoperation via a predetermined shutdown sequence referred to as the “FormFeed Mode”. Upon the pad formation system of an embodiment of thepresent invention being shut off (either a predetermined manual shutdown and/or via an automatic shutdown, as in one of the emergency shutdown situations described above), instead of immediately ceasingoperation, the bag module produces a few empty bags and the conveyorsystem continues to draw them in as if they were normal bags with foam.After a predetermined number of empty bags have been produced so thatthere are no bags containing rising foam in the droop zone between theoutput of the bagger and the input of the conveyor system, the entiresystem shuts down. Without the “form feed” feature bags with expandingfoam would be left behind in the droop zone unconstrained by theconveyor/platen system. These bags would expand into a size and shapethat the conveyor system would not be able to take in when the systemtried to restart. The expanded bags would have to be manually cut outfrom the web, and the web feed process would have to be started all overagain. Hence, with the form feed FF control sub-system the chain can bekept intact despite a stoppage or disruption. The number of unfilledbags generated is preferably sufficient in number to cover the bag chainweb distance extending from the end seal of the FIB machine to theintake 48 of the conveyance assembly ranging from, for example, 1 to 5(or more) bags, depending on the pad length. FIG. 5 shows an arrangementwherein preferably 2 unfilled bags (and possibly just 1) is sufficientto bridge the gap.

An embodiment of the present invention further comprises a fullyautomatic operation for pad formation. As previously mentioned,conventional flat pad molding systems involve a human operator to ensure(assist) in the process of transferring bags from the output of thebagger to the input of their dual conveyor systems. Without theassistance of an operator there is a tendency for bags to catch onvarious parts of the conveyor system. This can cause the bags to foldwhich reduces the internal volume available for the expanding foam oftento the point where the bags explode when they are constrained betweenthe conveyors. These bag explosions can damage the conveyor belts andeven spurt foam onto the operator, the product being packaged, and intothe general manufacturing area. The ability to provide a more fullyautomated pad formation system is facilitated by one (or anysub-combination or overall combination) of the below designatedfeatures:

A) There is structure and methodology that has the film/bag web remainintact until the bag web gets cut into individual bags at or near theexit of the conveyor molding system. Thus, the bags have less of achance to fold over as they do when they become individualized as whenthey are cut from the web at the exit of the bagger itself. Further, thepull, through effect of the present invention's design with continuousweb feed keeps the web/bags in line and facilitates a smooth feedthrough, without folding or jamming, through the molding zone. Also, bycutting the bags at the output end of the conveyor molding system thereis also avoided the possibility of poorly cut bags jamming up at theentry to the conveyor molding system. For instance, the cutting processunder conventional pad formation systems is not always reliable. Forinstance, it is quite common for a bag to be only partially cut or notcut at all as it exits the bagger. When this happens on current flatcushion molding systems and operator intervention is needed to prevent apotentially messy foam-up situation.

B) A further feature of an embodiment of the invention is thefacilitating of a fully automatic operation without the need for anyhuman intervention is found in the arrangement of an embodiment of thepresent invention wherein the cut wire is moved to the output end regionof the conveyor (within a foot or two or less of the conveyance assemblyoutput location) and is preferably run at a essentially constant voltageinstead of the impulse cutting required when it is done at the outputend of the bagger itself.

C) A further embodiment that facilitates the providing of a padformation system is one that provides a non-flat (e.g., a convolutedconveyor impression surface—which imparts its shape to the molded padand has more pulling power than a flat belted conveyor).

Operation

The overall arrangement of an embodiment is shown in FIG. 8 and furtherillustrated in FIGS. 9 and 10 from different viewpoints. With referenceto FIG. 8 there is provide an operational discussion for a preferredembodiment of a pad formation system of the present invention. As seenfrom FIG. 8, a suitable FIB system is provided such that its bag makingmodule generates a bag web or bag chain that features a plurality ofinterconnected bags with preferably a parallel (upstream/downstream)seal set between each bag pair. As further seen in FIG. 8, the FIBsystem is braced in relatively rigid fashion to the pad formationassembly having a conveyance assembly with a pair of conveyor componentssupported by a frame-structure having a plurality of floor mountedbraces (or some alternate support means as when dealing with a verticalconveyor component set).

In the FIG. 8 there is illustrated a conveyance assembly having arelatively horizontal bottom moving (driving) conveyor component with anon-flat surface and an above-positioned conveyor component shown asbeing a relatively rigid, solid platen extending for almost the entirelength of the underlying corrugated conveyor component (e.g., less thana foot extension differential and preferably less than a 6 inchdifferential in the conveyor component). The bag chain web is shown inFIG. 8 with a non-excessive bag droop and thus the sensor mounted on theupstream brace does not trigger an emergency shut down as the bag chainfeed is deemed not to be problematic (e.g., with too fast a bag feedrelative to the conveyor assembly to timely process downstream bagsthere is generated a disruption within the conveyance assembly as in theformation of bag droop path 114). Under normal operation with theconveyor assembly and FIB system appropriately synchronized, the bagchain properly enters into the passageway formed between the conveyorcomponents and then the convoluted conveyor drives the bag chain throughthe conveyance assembly. As a bag reaches the output end of theconveyance assembly a web link sensor senses for a gap between pads withmaterial in them which in turn triggers a downstream separation means orcutting mechanism to operate as in the bringing together of two jawswith at least one having a separation device as in a heated wire whichin the present invention is one that is maintained at a relativelyconstant temperature at all times while the pad formation system's powerbutton is on.

There is further preferably provided a gap separation sensing systempositioned downstream of the separation means to monitor whether gapsare separated as the bags are separated individually away from theupstream bag chain. Also, there is preferably further providedseparation enhancement means as well as downstream separate bag supportas in a roller conveyor platform with preferably one or more poweredrollers positioned for contact with a bag being separated such that apowered roller that is driven at a higher speed than that of general bagweb conveyance can implement a separation enhancement at the same timeor shortly after cut formation.

There is further preferably provided a shutdown logic sequence whereinthere is generated one or more non-filled sealed bags that arepositioned between the bag making module and the input end of theconveyance assembly such that when the pad formation system is restartedthere is not any full expanded and cured pads being fed into the inputend of the conveyance assembly. In an embodiment the operational controlsystem comprises a set of control boards (e.g., a central processingunit (CPU) and/or PFGA logic based control boards) that are groupedtogether and stored in a control panel (e.g., at the FIB unit) in aneasy access manner, although independent and/or semi-integrated systemare also featured under the present invention. FIG. 11 provides aschematic example of features of an operational control system generallyreferenced as CS which, in this embodiment, includes a plurality ofintegrated control sub-systems such as those listed below and shown incommunication with a central processing unit CPU (as but one example forcarrying out the above described individual sub-system activity andcoordinated sub-system interactions):

a) alarm control sub-system (AS);

b) FIB control sub-system (FC);

c) Conveyance system control sub-system (CC) (bag making advancementtiming);

d) Separation or cut mechanism control sub-system (SC);

e) Separation or cut confirmation control sub-system (SCN);

f) Pad chain jam sensor control sub-system (e.g., bag chain droop sensorsystem) (JC)

g) Web separation position sensing and time control sub-system (WS);

h) Heating mechanism control sub-system (HC);

i) Outfeed conveyance control sub-system (OC); and

j) Form feed control sub-system (FF)

Additional control sub-systems can also be separately provided or formedas part of the illustrated control system CS as in a toggle controlsub-system (not referenced) for adjusting between FIB direct pad cut andbag chain operation which in one embodiment includes a contact sensor(not shown) contact requirement between the FIB and pad formationassembly (such as at connection location 132 shown in FIG. 6).

As described above, at least some of the above described sub-systems orall or various sub-groupings are preferably integrated as in the abovedescribed activation of the FIB control sub-system FC instructing theFIB to advance an additional bag after receiving confirmation of thecutting of a bag by the separation confirmation control sub-system SCNwith appropriate sensing to determine if the cutting process took place.Further the alarm sub-system AS is preferably activated (e.g., audioand/or visual on a control panel such as that preexisting on the FIBsystem as represented by CP in FIGS. 9 and 10) when a sub-system such asthe separation confirmation control sub-system SCN senses a lack ofseparation. Similarly an alarm is triggered when the jam sensor controlsub-system JC with sensor 116 deems a pad chain jam up has occurred,preferably also coupled with a shut down via the various controlsub-systems such as that for the conveyance system and outfeedsub-system, if present. Also, an alarm status is preferably associatedwith a shutting down of appropriate active systems as in triggering theFIB sub-system to discontinue any activity in the FIG if currently in anactive mode, or when any of the various sub-systems is sensed as notoperating properly as in a lack of heat up in the heating mechanismjudged by heating mechanism control sub-system HC having associatedtherewith the above described heating mechanism control 91.

Addition examples of the above described integrated processing featuresof the present invention include the communication of cut mechanismcontrol sub-system SC in conjunction with the web separation positionsensing and time control sub-system WS which, in a preferred embodiment,features the above described sensor 80. Suitable conveyance system(e.g., conveyor belt movement or stoppage or speed adjustment) is alsopreferably integrated in conjunction with the separation means as in oneembodiment featuring a stopping signal with the associated sensedcutting location although other separation means designs provide for thecontinuous pad chain running (e.g., a synchronized moving cuttingmechanism as one example). Also the outfeed control sub-system providesfor the appropriate starting and stopping as well as relative conveyancerate differential as to place the chain in tension at the time ofcutting and rapidly move a cut pad away from the pad formation assembly.

The drawing provided herein illustrate some of the various embodimentsof the present invention as in those with corrugated belt and padconfigurations. Various alternate arrangements are also featured underthe present invention. All dimensions are in inches unless statedotherwise.

1.-29. (canceled)
 30. A foam cushion pad formation assembly, comprising:a conveyance assembly having at least one moving conveyor componentpresenting a pad shape formation surface, which pad shape formationsurface is arranged to shape pads of a pad chain received by saidconveyance assembly, said pads comprising enclosed foam material; aseparation device which is positioned downstream of a conveyanceassembly entrance as to separate shaped pads of the pad chain receivedby said conveyance assembly; and a separation confirmation sensingdevice positioned as to monitor performance of said separation device,and confirm complete separation of adjacent pads in a pad chain conveyedthrough said conveyance assembly.